Asphalt



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w. 'r. MULLEN 2,734,010

LAMINATED FLASHING MATERIALS Feb. 7, 1956 Filed June 29. 1953 ASPHALT IMPREGNATED AND CREPED PAPER ASPHALT WITH GLASS FIBER FILLER CREPED PAPER ASPHALT SHEET LEAD ALLOY ASPHALT THIN SHEET COPPER ASPHALT CREPED PAPER ASPHALT WITH GLASS FIBER FILLER ASPHALT IMPREGNATEC AND CREPED PAPER gaazaaxas a INVENTOR. WILLIAM T. MULLEN Unite Sttcs This invention. relates to laminated materials and more particularly to sheet material which is particularly useful in thev field of building construction.

It has heretofore been the. practice in the field of building construction to employ sheet copper for flashing, roofing covering. and the, like, of desired thickness, the preferred weight for flashing being identified as 16 ounce copper i. e. sheet copper, weighing 16 ounces to the square foot. While copper is. a desirable material for these purposes, because of its resistance to oxidation, it has objectiona-ble characteristics in that with expansion and contraction it, tends to lose its ductility and become brittle. It is also particularly susceptible to attack by acids present in certain building materials, and specifically in cinder blocks. The smooth surfaces of the copper, also, are not suited for the bonding thereto, of cement, mortar and the like.

The supply of copper is also rather limited at times and at such times increased building activity of housing projects and the like may also be desired and required.

v In my prior application, filedv May 29, 1951, Serial No. 228,948, now Patent No. 2,695,854, there is shown a laminated material which is particularly suitable for certain types of building construction but which by reason of the exposed copper face has an exterior surface which is subject to. acid attack, and. corrosion, may be injured by careless handling and use, and will not readily bond to the masonry in. which it is used.

It. is the principal object of the present invention, to provide sheet. material made. from a plurality of components in laminated form which is suitable for use in places where sheet copper has. heretofore been employed and which. has advantageous features not possessed by sheet copper.

It is a further, object of the present invention to provide.

sheet material; made from av plurality of components. in laminated. form which is suitable for use in places where sheet lead, except. for its cost, lack of alkali resistance, lack, of strength, andv lack of ability to retain its shape, might have been used, and which has advantageous features not possessed by sheet lead.

It is a further object of the present invention to provide a sheet material, made from a plurality of components in laminated form, which is suitable for use for fiashings inbuilding construction, for damp proofing, for membrane water proofing, for roofing covering, for shower pans, and for other purposes.

It is a further object of the present invention to provide sheet material, made from a plurality of components in laminated form, which is strong, light in weight, with a good body, permanent, waterproof, resistant to oxidation and corrosion, ductile, easily handled and capable of being bent to the required shape, retentive of its shape when bent, and which has numerous other advantages.

It is a further object of the present invention to provide sheet material of the character aforesaid which requires a minimum of scarce or diflicult to obtain components.

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It is a further, object of the present invention to provide sheet material of the character aforesaid inwhich the exterior or exposed faces are abrasivev resistant.

It. is a further object of the present invention to'provide sheet material of. the character aforesaid in which the metallic components are protected against corrosion or erosion.

It is a further object of'the present invention to provide sheet material of the character aforesaid which has two exposed faces of a character topcrmit it to be bonded to and securely held within the masonry construction in which the material is used.

It is. a further object of the present invention to provide a laminated material having an exterior face. construction which tends to channel out of the wall in which it is included any condensation hat might otherwise tend to accumulate.

Other objects and advantageous featuresv of the invention will. be apparent from the specification. and claims.

The nature and characteristic features of the invention will be more readily understood from. the following. description, taken in connection with the accompanying drawing forming part hereof, in. which:

The figure. is a fragmentary sectional view in perspecti've of sheet material in accordance with the present-- invention, with the thickness of the sheet, and of the laminations greatly exaggerated. for purposes of illustration.

It should of course, be understood that the description and drawing herein are illustrative merely, and. that various modifications and changes may be made in. the structure disclosed without departing, from the, spirit of the invention.

Referring more particularly to the. drawing, the sheet material in accordance with the present invention, asthere. illustrated; comprises a plurality of laminations of specific components, hereinafter more fully' described, in adherent engagement so as. to, prevent any slipping therebetween.

The outer or weather sheet 10. on one exposed face preferably consists of an outer protective layer of any desired type, one, suitable material being a paper lamina and, while any strong paper may be employed, it is preferrecfto use an asphalt impregnated. machine creped kraft' paper, such paper weighing, about. 45 pounds per ream having beerr found suitable,,with. an: asphalt. impregnatmg coating of the order of 30, to 35 pounds perv 10 0 square feet.

The innerface of the sheetIO preferably hasan asphalt coating 11* inadherent engagement therewith, the. coating 11 being of a thickness resulting from the application, of about 27 pounds of asphalt per. 1,000 square feet.

The coating 11 preferably has. imbedded therein, a glass fiber reinforcement for added strength, reductionof tendency to tear orrupture and freedom from. wicking efl ect with respect to moisture. For this purpose a. woven scrim of four glass fiber strands. per inch in each direction, with a; warp tensile strengthof 32 pounds per inch of width anda Weft orfillingtensile strength of 26 pounds per inch of width having been found satisfactory.

I'n adherent engagement also with. the lamina 11 an.

additional lamina 12. ofcreped kraft paper similar to the. lardniga- 10, but without the. asphalt impregnation, is, pro- V1 e In adherent engagementwith the lamina 12, a coating 13 of asphalt is provided similar in its characteristics to the lamina 11, but without any glass fiber included therein.

In adherent engagement with the lamina 13, a metallic lamina 14 is provided, preferably consisting of a lead alloy foil or sheet of a thickness of the order of 0.0025 inch. While any preferred alloy may be employed, an alloy consisting of about 99.8% of lead with antimony added to increase the stiffness has been found satisfactory.

A greater thickness of foil may be employed, if desired.

On the opposite face of the lamina 14, a coating 15 of asphalt is provided similar to the coating 13.

The inner face of the lamina 15 has in adherent engagement therewith a lamina 16 of electrolytic sheet copper of a thickness of the order of 0.00135 inch and of a weight of the order of one ounce per square foot. A greater thickness of the sheet copper may be employed, the total thickness of the lamina 13 and the lamina 15 preferably being in the range from about 0.002 inch to 0.007 inch.

The lamina 16 has, in adherent engagement therewith, a coating 17 of asphalt of the same or substantially the same characteristics as the coating 13.

The coating 17 is in adherent engagement with a lamina 18 of creped kraft paper, preferably similar in characteristics to the lamina 12.

In adherent engagement with the lamina 18, an asphalt coating 19 is provided, preferably having embedded therein glass fiber reinforcement similar in character to that previously described in the coating 11.

On the exterior of the asphalt coating 19, a layer 20 or sheet of paper is provided, preferably an asphalt impregnated and creped kraft paper like the layer 10.

The respective laminae are brought together in any desired manner and in adherent engagement as heretofore pointed out. The sheet material thus provided has been found suitable and acceptable for many of the uses for which 16 ounce copper sheets have heretofore been employed, requires only a small fraction of the total copper required for such copper sheets and weighs considerably less, thus reducing the cost of transportation and increasing the ease of handling.

The sheet material as thus provided seems to have an increased ductility and reduced brittleness in the metallic lamina 16, can be readily cut, bent, shaped and formed and when formed retains its shape. It is also permanent, waterproof and vaporproof, resistant to oxidation and corrosion both from the acids found in building constructions of cinder blocks and to alkaline action which occurs, for example, with the laitance of Portland cement. At the same time the metallic components are adequately protected against surface abrasion or rupture which might occur at the time the flashing is applied in the masonry construction, particularly when rough cinder blocks are employed. The laminated material also has a good body, is stronger and lower in manufacturing cost than comparable sheet copper or sheet lead, can be nailed and holds better than sheet metal and the overlapping joints at the edges or ends of the sheets in use may be readily sealed with asphalt. The relatively rough exterior surface is such as to permit the bonding of masonry materials such as cement therewith, and the corrugations which all extend in one direction tend to channel out of the wall any condensation that might accumulate.

I claim:

1. Sheet material comprising, a plurality of adherent laminations with a pair of outer laminations of protective abrasion resistant coverings, said outer laminationshaving rough exterior surfaces and having disposed therebetween separate laminations of lead foil and of electrolytic sheet copper with an adherent asphalt coating between the metallic laminations, said material being readilybendable and retaining the shape to which it'is bent.

2. Sheet material comprising a plurality of adherent laminations with a pair of outer laminations of asphalt impregnated and creped kraft paper having disposed therebetween separate laminations of asphalt, of lead foil and of electrolytic sheet copper with an adherent asphalt coating between the metallic laminations, said material being readily bendable and retaining the shape to which it is bent.

3. Sheet material comprising a first exteriorly cormgated lamina of asphalt impregnated paper, first asphaltic coating adherent to said first lamina and a second lamina of paper adherent to said first coating, a second asphaltic coating adherent to said second paper lamina, a third lamina of lead foil adherent to said second coating, a third asphaltic coating adherent to said third lamina, a fourth lamina of electrolytic sheet copper, a fourth asphaltic coating adherent to said fourth lamina, a fifth lamina of paper adherent to said fourth coating, a fifth asphaltic coating adherent to said fifth lamina and a sixth exteriorly corrugated lamina of asphalt impregnated paper adherent to said fifth coating, said sheet material being readily bendable and retaining the shape to which it is bent.

4. Sheet material as defined in claim 3 in which at least one of said first and sixth laminae is creped kraft paper.

5. Sheet material comprising a first lamina of asphalt impregnated and creped kraft paper, a first asphaltic coating adherent to said first lamina and having glass fibers incorporated therein, a second lamina of paper adherent to said first coating, a second asphaltic coating adherent to said second paper lamina, a third lamina of lead foil adherent to said second coating, a third asphaltic coating adherent to said third lamina, a fourth lamina of electrolytic sheet copper, a fourth asphaltic coating adherent to said fourth lamina, a fifth lamina of paper adherent to said fourth coating, a fifth asphaltic coating adherent to said fifth lamina and a sixth lamina of asphalt impregnated and creped kraft paper adherent to said fifth coatnig, said sheet material being readily bendable and retaining the shape to which it is bent.

6. Sheet material comprising a first lamina of asphalt impregnated and creped kraft paper, a first asphaltic coating adherent to said first lamina and having glass fibers incorporated therein, a second lamina of creped kraft paper adherent to said first coating, a second asphaltic coating adherent to said second paper lamina, a third lamina of lead foil adherent to said second coating, a third asphaltic coating adherent to said third lamina, a fourth lamina of electrolytic sheet copper, a fourth asphaltic coating adherent to said fourth lamina, a fifth lamina of creped kraft paper adherent to said fourth coating, a fifth asphaltic coating adherent to said fifth lamina and having glass fibers incorporated therein, and a sixth lamina of asphalt impregnated and creped kraft paper adherent to said fifth coating, said sheet material being readily bendable and retaining the shape to which it is bent.

References Cited in the file of this patent UNITED STATES PATENTS 1,529,463 Burnside Mar. 10, 1925 2,222,343 Wasserman Nov. 19, 1940 2,695,854 Mullen Nov. 30, 1954 

5. SHEET MATERIAL COMPRISING A FIRST LAMINA OF ASPHALT IMPREGNATED AND CREPED KRAFT PAPER, A FIRST ASPHALTIC COATING ADHERENT TO SAID FIRST LAMINA AND HAVING GLASS FIBERS INCORPORATED THEREIN, A SECOND LAMINA OF PAPER ADHERENT TO SAID FIRST COATING, A SECOND ASPHALTIC COATING ADHERENT TO SAID SECOND PAPER LAMINA, A THIRD LAMINA OF LEAD FOIL ADHERENT TO SAID SECOND COATING, A THIRD ASPHALTIC COATING ADHERENT TO SAID THIRD LAMINA, A FOURTH LAMINA OF ELECTROLYTIC SHEET COPPER, A FOURTH ASPHALTIC COATING ADHERENT TO SAID FOURTH LAMINA, A FIFTH LAMINA OF PAPER ADHERENT TO SAID FOURTH COATING, A FIFTH ASPHALTIC COATING ADHERENT TO SAID FIFTH LAMINA AND A SIXTH LAMINA OF ASPHALT IMPREGNATED AND CREPED KRAFT PAPER ADHERENT TO SAID FIFTH COATNIG, SAID SHEET MATERIAL BEING READILY BENDABLE AND RETAINING THE SHAPE TO WHICH IT IS BENT. 